Trumpf TruTool TKF 1500 User manual

Type
User manual

This manual is also suitable for

Operator´s manual
english
TruTool TKF 1500 (2C1), (2D1)
Table of contents
1Safety 4
1.1 General safety information 4
1.2 Specific safety information for beveler 4
2Description 6
2.1 Intended use 6
2.2 Technical data 7
2.3 Symbols 8
2.4 Noise and vibration information 9
3Setting work 10
3.1 Operating automatic feed 10
3.2 Inflating the bellows 10
3.3 Adjusting the angle of bevel 11
3.4 Adjusting the ram length 12
3.5 Setting material thickness 14
3.6 Selecting cutting tool 15
3.7 Driving rollers 16
3.8 Accessories included 16
Pedestal 16
Installing the chip box 17
4Operation 18
4.1 Overload indicator 19
4.2 Working with the TruTool TKF 1500 20
5Maintenance 23
5.1 Installing and disassembling the drive unit 24
5.2 Changing the cutting tool 25
Disassembling the cutting tool 26
Installing and setting the cutting tool 27
5.3 Regrinding cutting tool 28
5.4 Change the sliding sleeve 28
5.5 Lubricating the impeller 30
5.6 Changing the driving roller 30
5.7 Changing the power cable 31
5.8 Replacing carbon brushes 32
2Table of contents 2011-08-22 E612EN_02
6Accessories and consumables 33
6.1 Ordering consumables 33
7Help in the case of problems 35
8Appendix: Guarantee, declaration of con-
formity, replacement parts lists
36
E612EN_02 2011-08-22 Table of contents 3
1. Safety
1.1 General safety information
Read all the safety information and instructions including
those in the brochure also supplied.
Failure to comply with the safety information and instructions
can cause electric shock, burns and/or serious injury.
Retain all the safety information and instructions for future
use.
Electrical voltage! Risk of fatal injury due to electric shock!
ØRemove the plug from the plug socket before undertaking
any maintenance work on the machine.
ØCheck the plug, cable and machine for damage each time
before using the machine.
ØKeep the machine dry and do not operate it in damp rooms.
ØConnect the fault current (FI) circuit breaker with a maximum
breaking current of 30 mA when using the electric tool out-
side.
ØProtect the machine cable in areas where there are sparks.
ØOnly use original TRUMPF accessories.
Damage to the machine due to improper handling.
ØWear safety glasses, hearing protection, protective gloves
and work shoes when working at the machine.
ØDo not insert the plug unless the machine is switched off.
After use, pull out the power plug.
ØDo not use the cable to carry the machine.
ØMaintenance may be carried out by trained specialist techni-
cians only.
1.2 Specific safety information for
beveler
Electrical voltage! Risk of fatal injury due to electric shock!
ØAlways lay the power cable away from the back of the
device and do not pull it over sharp edges.
ØDo not perform any work that may cause the machine to
come into contact with hidden power lines or its own cable.
Contact with a live conductor can cause metallic machine
parts to become live and can lead to an electric shock.
4Safety 2011-08-22 E612EN_02
DANGER
WARNING
DANGER
Risk of injury to hands.
ØDo not reach into the processing line with your hands.
ØUse both hands to hold the machine.
Risk of injury from hot and sharp chips!
Chips exit the chip ejector at high speed.
ØUse the chip box.
Risk of injury from falling machinery
ØThe entire weight of the machine must be taken up after
machining the workpiece.
Damage to property due to improper handling.
Collisions could result from an erroneous setting of the
machine.
ØRotate the eccentric shaft one full turn in a clockwise direc-
tion using the Allen key provided. If no collisions can be
detected, remove the Allen key and put the machine into
operation in accordance with regulations.
E612EN_02 2011-08-22 Specific safety information for beveler 5
WARNING
WARNING
WARNING
CAUTION
2. Description
1 Gear head
2 Drive unit
3 Eccentric shaft
4 Overload indicator
5 Grease nipple
6 Valve (2x)
7 Stop roller
8 Impeller
9 Feed lever
10 Bellows (2x)
11 Clamping lever
12 Cutting tool
13 On/Off switch
TruTool TKF 1500 beveler (2C1), (2D1) Fig. 56390
2.1 Intended use
The TRUMPF TruTool TKF 1500 beveler (2C1), (2D1) is an
electrical powered hand-held device designed for the following
applications:
Preparation of all K-, V-, X-and Y-shaped welding grooves
usual for gas and electrical fusion welding with various con-
6Description 2011-08-22 E612EN_02
tinuously adjustable angles of bevel and continuously adjust-
able lengths of bevels.
Forming of uniform, oxide-free, bright metallic welding bevel
edges in steel and aluminum.
Beveling of edges on large, bulky workpieces by using the
beveler as a hand-held device.
The TRUMPF TruTool TKF 1500 beveler (2D1) also offers 2-
gear changing for modifying the working speed.
2.2 Technical data
Other countries USA
Values
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz
Max. length of bevel "ls" continuously adjustable:
Mild steel with 400 N/
mm²
15 mm 0.59 in
Mild steel with 600 N/
mm²
9 mm 0.354 in
Working speed 2 m/min 6.55 ft/min
Nominal power con-
sumption
2000 W -
Nominal current -15 A
Stroke rate with nominal
load
370/min 340/min 340/min 340/min
Weight 24 kg 52.9 lbs
Material thicknesses:
Min. 6 mm 0.236 in
Max. 40 mm 1.57 in
Angle of bevel "ß" con-
tinuously adjustable
20°-55° 20°-55°
Safety class II / II /
Tab. 1
Other countries USA
Values
Voltage 230 V 120 V 110 V 120 V
Frequency 50/60 Hz 50/60 Hz
Max. length of bevel "ls" continuously adjustable:
Mild steel with 400 N/
mm²
15 mm (1st + 2nd gear) 0.59 in
Mild steel with 600 N/
mm²
11 mm (1st gear)
9 mm (2nd gear)
0.433 in
0.354 in
E612EN_02 2011-08-22 Technical data 7
TruTool TKF 1500 (2C1)
TruTool TKF 1500 (2D1)
Other countries USA
Values
Working speed 1.25 m/min (1st gear)
2 m/min (2nd gear)
4.1 ft/min
(1st gear)
6.55 ft/min
(2nd gear)
Nominal power con-
sumption
2000 W -
Nominal current -15 A
Stroke rate with nominal
load
230/min
(1st
gear)
370/min
(2nd
gear)
170/min
(1st
gear)
340/min
(2nd
gear)
170/min
(1st
gear)
340/min
(2nd
gear)
170/min
(1st gear)
340/min
(2nd gear)
Weight with guide han-
dle
27 kg 59.5 lbs
Material thicknesses:
Min. 6 mm 0.236 in
Max. 40 mm 1.57 in
Angle of bevel "ß" con-
tinuously adjustable
20°-55° 20°-55°
Safety class II / II /
Tab. 2
2.3 Symbols
Note
The following symbols are important for reading and understand-
ing the instruction manual. The correct interpretation of the sym-
bols will help you operate the machine better and safer.
Symbol Name Meaning
Read operating manual Read the operator's manual and safety information in
their entirety before starting up the machine. Closely
follow the instructions given.
Safety class II Indicates a doubly insulated tool.
Alternating current Type or property of current
V Volt Voltage
A Ampere Current, current input
Hz Hertz Frequency (oscillations per second)
W Watt Power, power input
mm Millimeters Dimensions e.g.: material thickness, chamfer length
in Inches Dimensions e.g.: material thickness, chamfer length
noIdle speed Revolution speed without load
8Symbols 2011-08-22 E612EN_02
TruTool TKF 1500 (2D1)
Symbol Name Meaning
.../min Revolutions/strokes per minute Revolution speed, stroke rate per minute
Tab. 3
2.4 Noise and vibration information
Noise emission value may be exceeded.
ØWear hearing protection.
Vibration emission value may be exceeded.
ØSelect tools correctly and replace them promptly when they
show wear.
ØMaintenance may be carried out by trained specialist techni-
cians only.
ØEstablish additional safety precautions for the protection of
the operator against the effects of vibrations (e.g. keeping
hands warm, organizing the work sequences, machining with
normal feed power).
Notes
The specified vibration emission value was measured in
accordance with a standardized testing procedure and can
be used to compare one electric tool with another.
The specified vibration emission value can also be applied
for a provisional estimate of the vibration load.
Times during which either the machine is switched off or run-
ning but not actually in use can considerably reduce the
vibration load during the entire working period.
Times during which the machine works independently and
self-propelled do not have to be calculated.
Designation of measured value Unit Value
according
to
EN 60745
Vibration emission value ah (vector sum of
three directions)
m/s212.1
Uncertainty K for vibration emission value m/s22.5
A-class acoustic pressure level LPA typi-
cally
dB (A) 87
A-class acoustic power level LWA typically dB (A) 98
Uncertainty K for noise emission value dB 3
Tab. 4
E612EN_02 2011-08-22 Noise and vibration information 9
WARNING
WARNING
3. Setting work
Damage to property due to improper handling.
Collisions could result from an erroneous setting of the
machine.
ØRotate the eccentric shaft one full turn in a clockwise direc-
tion using the Allen key provided. If no collisions can be
detected, remove the Allen key and put the machine into
operation in accordance with regulations.
3.1 Operating automatic feed
9 Feed lever
11 Clamping lever
A Clamping position "open"
B Clamping position "zero"
C Clamping position "clamp"
D Feed-index
Fig. 56391
3.2 Inflating the bellows
Notes
If the pressure in the bellows is too low, then there will be a
danger that the machine will not be guided u close to the
sheet edge and that the bevel will be of nonuniform size.
10 Setting work 2011-08-22 E612EN_02
CAUTION
If the pressure in the bellows is too high, then a very high
drive force will be required and the drive will display an over-
load. If this is the case, then the pressure in the bellows can
be reduced down as far as 6 bar.
Damage to property due to improper handling.
ØCheck the bellows regularly
1. Set clamping lever (11) to position "0" (see "Fig. 56391", pg.
10).
2. Remove the valve cap.
3. Screw the pump (Order No. 0384723) onto the valve (6).
4. Inflate to 7.5 bar (108 psi).
5. Quickly unscrew the pump from the valve (6).
6. Replace the valve cap.
The system is now sealed.
Note
The air pressure in the bellows influences the automotive
function and must be equal on both sides.
7. Inflate the second set of bellows (10) in the same way.
3.3 Adjusting the angle of bevel
Notes
The angle of bevel "ß" is continuously adjustable between
20° and 55°.
The machine can be clamped to the sheet and/or the drive
unit can be released in order to facilitate the setting adjust-
ment (see "Installing and disassembling the drive unit", pg.
24).
E612EN_02 2011-08-22 Operating automatic feed 11
CAUTION
8 Impeller
35 Spindle for setting the material
thickness
36 Hex. screw
Fig. 56393
1. Undo the hex. screw (36).
2. Set the desired angle in accordance with the scale.
3. Retighten the hex. screw (36).
3.4 Adjusting the ram length
s Material thickness
β Angle of bevel
ls Length of bevel
hs Height of bevel
b Width of bevel
h Residual height
Length of bevel and angle of bevel Fig. 9664
The values highlighted in boldface in the following table can
not be processed with the "narrow" driving roller. The "wide" driv-
ing roller must be used here (see "Driving rollers", pg. 16).
12 Operating automatic feed 2011-08-22 E612EN_02
W 8 7 6 5 4 3 2 1 0 mm
ß 55° 14.5 13.3 12.1 10.8 9.7 8.4 7.2 6.0 4.8 ls
11.9 10.9 9.9 8.9 7.9 6.9 5.9 4.9 3.9 b
8.3 7.7 7.0 6.2 5.6 4.8 4.2 3.5 2.8 hs
ß 45° 15 13.6 12.12 10.8 9.4 8 6.5 5.1 3.7 ls
10.6 9.6 8.6 7.6 6.6 5.6 4.6 3.6 2.6 b
10.6 9.6 8.6 7.6 6.6 5.6 4.6 3.6 2.6 hs
ß 37.5° 15.5 13.8 12.2 10.5 8.9 7.3 5.6 4 2.4 ls
9.4 8.4 7.4 6.4 5.4 4.4 3.4 2.4 1.4 b
12.3 11 9.6 8.3 75.8 4.4 3.1 1.9 hs
ß 30° - 15 13 11 97531ls
- 7.5 6.5 5.5 4.5 3.5 2.5 1.5 0.5 b
-13 11.2 9.5 7.8 6 4.3 2.6 0.8 hs
ß 20° - - 15 12.2 9.2 6.2 3.3 - - Is
- - 5.1 4.2 3.1 2.1 1.1 - - b
- - 14 11.4 8.6 5.8 3.1 - - hs
ß Angle of bevel
ls Length of bevel
h Height of bevel
b Width of bevel
W Scale value which must be adjusted on the
crank sliding block
Tab. 5
Example for working with the table:
β desired 30°
ls13 mm
W (from the table) 6
Tab. 6
E612EN_02 2011-08-22 Operating automatic feed 13
7 Stop roller
17 Pressure die
18 Hex. screw
19 Crank sliding block
B Reference point
Fig. 56392
1. Undo the hex. screw (18).
2. Consult the table to find the desired length of bevel/ram
length ls and the associated scale value W (see "Tab. 5", pg.
13).
Note
Observe angle of bevel ß.
3. Rotate the crank sliding block (19) until the scale value W on
the crank sliding block lines up with the reference point B.
4. Tighten the hex. screw (18).
3.5 Setting material thickness
1. Set the machine on the sheet, setting the clamping lever (11)
to the "zero" position while doing so (see "Fig. 56391", pg.
10).
Note
Make sure that the cutting tool is at the upper dead point.
The machine is on top supported by four rollers, and can be
pushed along the sheet edge up until the pressure die (17)
and the stop roller (7) (see "Fig. 56392", pg. 14).
14 Operating automatic feed 2011-08-22 E612EN_02
2. Undo the spindle (35) by pushing it up and out of the locking
device.
3. Tighten the impeller (8) against the lower sheet edge by turn-
ing the spindle (35).
4. Lock the spindle (35) back into place by sliding it down-
wards, returning beforehand to the last home position if nec-
essary (see "Fig. 56393", pg. 12).
3.6 Selecting cutting tool
Cutting tool standard high-tensile high-tensile
5575
Aluminum
Order No. 1559722 1559724 1559721 0005014
Application General mild
steels
Higher-tensile
mild steels
Higher-tensile
mild steels,
increased serv-
ice life
Aluminum alloys
Angle x = x = 15°
Regrinding
reserve
10 mm
Regrinding dia-
gram
Cutting tools for the TruTool TKF 1500 beveler (2C1), (2D1) Tab. 7
Assembly and setting work: (see "Changing the cutting tool", pg.
25).
E612EN_02 2011-08-22 Selecting cutting tool 15
3.7 Driving rollers
Driving roller wide narrow
Order No. 1450515 1418094
Characteristic feature Standard roller
Can be used for all chamfer sizes.
Does not leave marks behind on
the workpiece.
Restrictions - Do not use for those chamfer
sizes printed in bold in the
table(see "Tab. 5", pg. 13).
It is not possible to refinish the
bevel.
Driving rollers for the TruTool TKF 1500 beveler (2C1), (2D1) Tab. 8
Assembly: (see "Changing the driving roller", pg. 30).
3.8 Accessories included
Pedestal
Fig. 60840
16 Driving rollers 2011-08-22 E612EN_02
The machine can be stored on the pedestal when it is not in
use.
Installing the chip box
Chips that fall away during machining are collected in the chip
box.
1 Locking bar 2 Chip box
Machine with chip box Fig. 56396
1. Turn the locking bar (1) upward.
2. Push the chip box (2) onto the clamping plate.
3. Turn the locking bar (1) downward.
The chip box is secured against dropping out.
E612EN_02 2011-08-22 Accessories included 17
4. Operation
Damage to the machine due to improper handling.
ØMake sure the machine is always in a stable position when
operating it.
ØNever touch the tool while the machine is running.
ØAlways operate the machine away from your body.
ØDo not operate the machine above your head.
Damage to property due to excessively high line voltage
Motor damage
ØCheck the line voltage. The power supply voltage must cor-
respond to the information on the nameplate of the machine.
ØWhen using an extension cord that is longer than 5 m, the
cord must have a line diameter of at least 2.5 mm².
Damage to property due to improper handling.
Collisions could result from an erroneous setting of the
machine.
ØRotate the eccentric shaft one full turn in a clockwise direc-
tion using the Allen key provided. If no collisions can be
detected, remove the Allen key and put the machine into
operation in accordance with regulations.
Electrical voltage! Risk of fatal injury due to electric shock!
ØAlways lay the power cable away from the back of the
device and do not pull it over sharp edges.
ØDo not perform any work that may cause the machine to
come into contact with hidden power lines or its own cable.
Contact with a live conductor can cause metallic machine
parts to become live and can lead to an electric shock.
During operation, at an interval of approx. 20 m, the grease
nipple (5) on the supporting body should be lubricated with
one or two squirts of grease. Doing so prolongs the service
life of the cutting tool (see "Fig. 56390", pg. 6).
Observe the overload indicator (4) during machining. If an
overload is indicated, stop machine operation (see "Help in
the case of problems", pg. 35).
In order to improve the cutting result and increase the service
life of the cutting tool, coat the cutting track with oil before
machining the workpiece.
18 Operation 2011-08-22 E612EN_02
WARNING
CAUTION
CAUTION
DANGER
Monitoring during operation
Lubricating oil
Component Oil
Steel Punching and nibbling oil (0.5 l, Order No. 0103387)
Aluminum Punching and nibbling oil for aluminum (1 l, Order No.
0125874)
Tab. 9
4.1 Overload indicator
Damage to property due to improper handling.
The machine can become damaged when working with the
machine for extended periods when it is overloaded.
ØMonitor the machine during machining.
4 Overload indicator pin
Fig. 56398
The integrated overload protection protects the drive from being
damaged in the event of an overload.
E.g. when the slag is too think, due to fluctuations in material
thickness or due to obstructions such as clamping screws, etc.
E612EN_02 2011-08-22 Overload indicator 19
CAUTION
The overload indicator pin (4) moves only minimally. The
machine is not overloaded.
The overload indicator pin (4) swings away to the right. This
indicates an overload. Stop the machine.
4.2 Working with the TruTool TKF 1500
Risk of injury from hot and sharp chips!
Chips exit the chip ejector at high speed.
ØUse the chip box.
Damage to property due to turning the gear switch during
operation.
Damage to the gearbox can be a consequence.
ØUse the gear switch only when the motor is running down or
at rest.
7 Stop roller
9 Feed lever
11 Clamping lever
13 On/Off switch
22 Motor handle
23 Release switch
37 2-gear changing
A Front rollers
B Rear rollers
Placing the machine on the workpiece Fig. 56397
1. Performing setting work (see "Setting work", pg. 10).
2. For TruTool TKF 1500 (2D1): select gear (37).
20 Overload indicator 2011-08-22 E612EN_02
Signs of overloading
WARNING
CAUTION
Switching the machine on
and working
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Trumpf TruTool TKF 1500 User manual

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User manual
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